Sr. No.

Criteria Operators

1 Literacy
1.1 Can read & write English, Marathi, Hindi 2
Conversant with MS Office - Word, Excel, Powerpoint,
1.2 1
Outlook
1.3 Conversant with SAP 1
1.4 Conversant with Raypro/ Proplast
1.5 AutoCAD NA
2 Discipline
2.1 Punctuality, Sincerity, speed in action, 3
3 Operation knowledge/ Proficiency - Molding
3.1 Can operate Arburg machines 1
3.2 Can operatre Engel machines 1
3.3 Can discriminate/ identify raw materials 1
3.4 Can start/stop Hot runner system 2
Aware of temperature profile setting for different
3.5 2
materials
3.6 Counting & weighing of molded parts 3
3.7 Use of Hoist 1
3.8 Use of inspection gages 3
3.9 Use of Raypro/ Proplast 2
Operation of peripherals like robot, sprue-picker, MTC
3.10 2
etc.,
3.11 Can load & unload molds 2
3.12 Can set process parameters & Optimize 1
Aware of different temperature profiles for material
3.13 2
processing based on barrel capacity
3.14 Can calculate tonnage based on projected area NA
3.15 Can set hold-on period based on gate freeze time NA
Aware of relation between RPM/ cirumferencial speed/
3.16 NA
surface speed
3.17 Apply & set fill phase & pressure phase judiciously NA
3.18 Can do Core setting considering safety NA
3.19 Apply cycle time saving techniques NA
3.20 Understand the PVT diagram NA
3.21 Can set Robot for new parts NA
3.22 Can make grippers for new parts NA
3.23 Can program robot for new parts NA
 3.24 Can trouble shoot machine problems 1
3.25 Can trouble shoot process problems 1
3.26 Can trouble shoot Hot runner problems 1
3.27 Can trouble shoot chiller problems 1
3.28 Can trouble shoot MTC problems 1
3.29 Can trouble shoot Dryer/ loader problems 1
3.30 Can trouble shoot ejector/ core issues on mold 1
3.31 Can trouble shoot Robot problems 1
3.32 Can trouble shoot problems pertained to molds 1
3.33 Can read electrical schematic circuit diagram NA
3.34 Can read hydraulic circuit diagram & troubleshoot NA
3.35 Can read technical drawing 1
3.36 Can trouble shoot Compressors NA
3.37 Can trouble shoot DG Set problems NA
3.38 Can generate MIS reports from Raypro/Proplast NA
3.39 Knows how to calculate & interpret OEE? 1
3.40 Knows the difference between T-OEE & OEE 1
3.41 Can generate PPM records 1
3.42 Can do Root cause analysis & rapid problem solving 1
3.43 Aware of Quality tools 2
3.44 Can decide machine (buying) based on specifications NA

Operation knowledge/ Proficiency - Fastener Assembly

7
7.1 Can read technical drawing
7.2 Can operate Ruhlamat river assembly machine
7.3 Can operate Collar punching machine
7.4 Can operate Glass fastener assembly machine
7.5 Can operate Hot melt machine
7.6 Can operate toggle press for collar punching
7.7 Can operate Swivel assembly machine
7.8 Can operate Edge Clip assembly machine
7.9 Can trouble shoot problems on assembly machines
7.10 Can do Motion study & Work element study
7.11 Can do Load balancing on the line
7.12 Can minimize cycle time and increase output
7.13 Aware of SMED procedures
7.14 Can do Root cause analysis & rapid problem solving
8 Understanding of methods & standards
8.1 Can read & follow the SoP
8.2 Planning & delivery
8.3 Aware of material pre-drying procedure
8.4 Aware of hot runner starting procedure
8.5 Aware of machine start/stop procedure
8.6 Aware of Order closing procedure
8.7 Aware of MRN generating procedure
8.8 Aware of material re-grinding procedure
8.9 Aware of hopper cleaning procedure
8.10 Aware of barrel purging procedure
8.11 Can identify labels/ Carton specifications
8.12 Discriminate box & bag labels
8.13 Aware of packing methods
8.14 Aware of SMED/ Mold change procedure
8.15 Aware of QMS systems - General
8.16 Aware of QMS systems - Clausewise
Collaborate with PPC/ Maintenance team for maximized
8.17
utilization
8.18 Aware of lubrication handling/ disposal procedures
8.19 Aware of Set up Approval procedures
8.20 Aware of Process monitoring procedures
8.21 Can do PFMEA/ PPAP
8.22 Aware of 5 Core Tools
9 Safety Awareness
9.1 Aware of PPE usage
9.2 Aware of Aspect-Impact procedures
9.3 Safe operation of machine/ peripherals
9.4 Aware of Near-miss reporting procedures
9.5 Trained in First Aid
9.6 Trained in fire fighting
9.7 Aware of color codes for trash bins
9.8 Aware of emergency evacuation plan/ procedures
9.9 Aware of importance of illumination
9.10 Aware of lubrication handling/ disposal procedures
10 ATOMS
10.1 Aware of 7 elements of ATOMS
10.2 Can practice 5S in his desk// workstation
10.3 Can teach other 5S practices
10.4 Can adapt Flow concepts
10.5 Can teach others the flow concepts
10.6 Aware of QC tools & application
10.7 Aware of SPC calculations & its applications
10.8 Aware of Six Sigma/ DoE/
10.9 Can do Motion study & Work element study
10.10 Can do Value Stream mapping
10.11 Can identify Wastes & the root cause for the same
10.12 Can minimize/ eliminate Wastes in the process
10.13 Can reduce throughput time
10.14 Can do calculations for Standard WIP/ Supermarket
10.15 Aware of Kanban & its calculations
10.16 Aware of Internal logistics/ container calculations
10.17 Can design workstation based on ergonomics
10.18 Can do process optimization
10.19 Aware of TPM - its main 5 pillars
10.20 Can motivate teams on Idea generation/ Kaizens
11 Dealing with people
Establishing focus - Aligning the functional goal with
11.1 strategy of the organization, creating stretch, PMS, setting
& sharing of goals, feedback

Motivational support - People development

11.2 (acknowledges, recognizes, energizes, address morale
issues, pep talks, provide insights)

Fostering teamwork - lead by example, demonstrate,

11.3 bringing synergy, learn together, promoting cooperation,
fair treatment

Empowering others - Effective delegatoin, convey

11.4 confidence in capabilities, allowing freedom to accomplish
tasks, encouraging team to resolve problems on their own

Managing Change - establish structures for orderly

implementation of change, ability to look ahead, taking
11.5
lead in setting new directions, look for innovative
solutions, supports various change management activities

12 Communication & Influencing

Communication - attention to communication, active

listening, sharing of information, expresses ideas
12.1
concisely, summarization, persuvasive communication,
tailored communication to reach audience effectively.

Interpersonal awareness: Empathy, ability to notice,

interpret, anticipate other's concerns, understands
strengths and weakness or others, making others feel
comfortable, influence others, gain others' support for
ideas, proposals, projects & solutions
12.2

Collaborative relationships: acknowledging others'

perspectives, showing interest in others, express gratitude
12.3
& appreciation for support, ability to develop, maintain &
strengthen relationships, providing assistance & support
 Customer Orientation: Win the confidence of customers
(internal & external), demonstrates concern for satifying
their needs, finding a win-win situation, measure & track
customer satisfaction, presents cheeful, positive manners
to customers
12.4
13 Business Competentcies

Problem Solving: Diagnostic information gathering,

analytical thinking using logical, systematic, sequential
approach, identifying abnormalities, differential
diagnostics, technical expertise, forward thinking
13.1

Entrepreneurial orientation: Self-drive & intiative,

seizing opportunties, stays abreast of business, market
information, fostering innovation, promotes
entrepreneurial behavior in others, Decisiveness - Tough &
timely decisions
13.2
Result Orientation: Stretch goals, develops clear goals for
projects, finds ways to measure goals, maintains
commitment to accomplish the goal, focus on processes to
achieve the goals
13.3
Thoroughness: Ensures correct & accurate information,
verifies data & information, sets procedures to ensure
highest quality of work, carefully prepares presentations,
Data accuracy
13.4
13.5 Decisiveness: Tough & timely decisions,
14 Self Management

Self- confidence: Conceptual & intellectual ability, ready

to change, Agile, can-do attitude, updating knowledge,
14.1

Stress Management: Self-control under pressure, keep

calm under stress, handling multiple tasks, maintains
sense of humor, manages own behavior under stress
14.2
Credibility: demonstrates as responsible, reliable &
trustworthy, does what is commited, respects
confidentiality, honest & forthright, owning responsibiilty,
no blaming
14.3
Leaders only

Value Stream Functional

Tool Setters Supervisors Team Leader
Leader Head

3 3 4 4 4

2 3 4 4 4

2 3 3 NA NA

NA NA NA NA NA

3 4 4 4 4

3 4 4 NA NA
3 4 4 NA NA
3 4 4 NA NA
3 4 4 NA NA

3 4 4 NA NA

3 4 4 NA NA
4 4 4 NA NA
4 4 4 4 4
2 3 4 3 3

4 4 4 NA NA

4 4 4 NA NA
3 4 4 NA NA

4 4 4 NA NA

2 3 4 4 4
2 3 4 4 4

2 3 4 4 4

2 3 4 4 4
4 4 4 NA NA
4 4 4 4 4
4 4 4 4 4
4 4 4 NA NA
4 4 4 NA NA
4 4 4 NA NA
2 2 2 NA NA
3 4 4 NA NA
2 2 2 NA NA
2 2 2 NA NA
2 2 2 NA NA
2 2 2 NA NA
3 4 4 NA NA
3 4 4 NA NA
3 4 4 4 4
1 2 2 NA NA
1 2 2 2 2
2 3 4 4 4
NA NA NA NA NA
NA NA NA NA NA
2 3 4 4 4
2 4 4 4 4
2 4 4 4 4
2 4 4 4 4
3 4 4 4 4
3 4 4 4 4
1 2 3 4 4
ORGANISA
TIONAL
FUNCTIONAL /TECHNICAL

SOFT SKILL Behavioural

PERSONAL
Sr. No. Criteria Operators

1 Literacy
1.1 Can read & write English, Marathi, Hindi 2
Conversant with MS Office - Word, Excel, Powerpoint,
1.2 1
Outlook
1.3 Conversant with SAP 1
1.4 Conversant with Raypro/ Proplast 1
1.5 AutoCAD NA
2 Discipline
2.1 Punctuality, Sincerity, speed in action, 3
3 Operation knowledge/ Proficiency - Molding
3.1 Can operate Arburg machines 1
3.2 Can operatre Engel machines 1
3.3 Can discriminate/ identify raw materials 1
3.4 Can start/stop Hot runner system 2
Aware of temperature profile setting for different
3.5 2
materials
3.6 Counting & weighing of molded parts 3
3.7 Use of Hoist 1
3.8 Use of inspection gages 3
3.9 Use of Raypro/ Proplast 2
Operation of peripherals like robot, sprue-picker, MTC
3.10 2
etc.,
3.11 Can load & unload molds 2
3.12 Can set process parameters & Optimize 1
Aware of different temperature profiles for material
3.13 2
processing based on barrel capacity
3.14 Can calculate tonnage based on projected area NA
3.15 Can set hold-on period based on gate freeze time NA
Aware of relation between RPM/ cirumferencial speed/
3.16 NA
surface speed
3.17 Apply & set fill phase & pressure phase judiciously NA
3.18 Can do Core setting considering safety NA
3.19 Apply cycle time saving techniques NA
3.20 Understand the PVT diagram NA
3.21 Can set Robot for new parts NA
3.22 Can make grippers for new parts NA
3.23 Can program robot for new parts NA
 3.24 Can trouble shoot machine problems 1
3.25 Can trouble shoot process problems 1
3.26 Can trouble shoot Hot runner problems 1
3.27 Can trouble shoot chiller problems 1
3.28 Can trouble shoot MTC problems 1
3.29 Can trouble shoot Dryer/ loader problems 1
3.30 Can trouble shoot ejector/ core issues on mold 1
3.31 Can trouble shoot Robot problems 1
3.32 Can trouble shoot problems pertained to molds 1
3.33 Can read electrical schematic circuit diagram NA
3.34 Can read hydraulic circuit diagram & troubleshoot NA
3.35 Can read technical drawing 1
3.36 Can trouble shoot Compressors NA
3.37 Can trouble shoot DG Set problems NA
3.38 Can generate MIS reports from Raypro/Proplast NA
3.39 Knows how to calculate & interpret OEE? 1
3.40 Knows the difference between T-OEE & OEE 1
3.41 Can generate PPM records 1
3.42 Can do Root cause analysis & rapid problem solving 1
3.43 Aware of Quality tools 2
3.44 Can decide machine (buying) based on specifications NA
8 Understanding of methods & standards
8.1 Can read & follow the SoP
8.2 Planning & delivery
8.3 Aware of material pre-drying procedure
8.4 Aware of hot runner starting procedure
8.5 Aware of machine start/stop procedure
8.6 Aware of Order closing procedure
8.7 Aware of MRN generating procedure
8.8 Aware of material re-grinding procedure
8.9 Aware of hopper cleaning procedure
8.10 Aware of barrel purging procedure
8.11 Can identify labels/ Carton specifications
8.12 Discriminate box & bag labels
8.13 Aware of packing methods
8.14 Aware of SMED/ Mold change procedure
8.15 Aware of QMS systems - General
8.16 Aware of QMS systems - Clausewise
Collaborate with PPC/ Maintenance team for maximized
8.17
utilization
8.18 Aware of lubrication handling/ disposal procedures
8.19 Aware of Set up Approval procedures
8.20 Aware of Process monitoring procedures
8.21 Can do PFMEA/ PPAP
8.22 Aware of 5 Core Tools
9 Safety Awareness
9.1 Aware of PPE usage
9.2 Aware of Aspect-Impact procedures
9.3 Safe operation of machine/ peripherals
9.4 Aware of Near-miss reporting procedures
9.5 Trained in First Aid
9.6 Trained in fire fighting
9.7 Aware of color codes for trash bins
9.8 Aware of emergency evacuation plan/ procedures
9.9 Aware of importance of illumination
9.10 Aware of lubrication handling/ disposal procedures
10 ATOMS
10.1 Aware of 7 elements of ATOMS
10.2 Can practice 5S in his desk// workstation
10.3 Can teach other 5S practices
10.4 Can adapt Flow concepts
10.5 Can teach others the flow concepts
10.6 Aware of QC tools & application
10.7 Aware of SPC calculations & its applications
10.8 Aware of Six Sigma/ DoE/
10.9 Can do Motion study & Work element study
10.10 Can do Value Stream mapping
10.11 Can identify Wastes & the root cause for the same
10.12 Can minimize/ eliminate Wastes in the process
10.13 Can reduce throughput time
10.14 Can do calculations for Standard WIP/ Supermarket
10.15 Aware of Kanban & its calculations
10.16 Aware of Internal logistics/ container calculations
10.17 Can design workstation based on ergonomics
10.18 Can do process optimization
10.19 Aware of TPM - its main 5 pillars
10.20 Can motivate teams on Idea generation/ Kaizens
11 Dealing with people
Establishing focus - Aligning the functional goal with
11.1 strategy of the organization, creating stretch, PMS, setting
& sharing of goals, feedback

Motivational support - People development

11.2 (acknowledges, recognizes, energizes, address morale
issues, pep talks, provide insights)

Fostering teamwork - lead by example, demonstrate,

11.3 bringing synergy, learn together, promoting cooperation,
fair treatment
 Empowering others - Effective delegatoin, convey
11.4 confidence in capabilities, allowing freedom to accomplish
tasks, encouraging team to resolve problems on their own

Managing Change - establish structures for orderly

implementation of change, ability to look ahead, taking
11.5
lead in setting new directions, look for innovative
solutions, supports various change management activities

12 Communication & Influencing

Communication - attention to communication, active

listening, sharing of information, expresses ideas
12.1
concisely, summarization, persuvasive communication,
tailored communication to reach audience effectively.

Interpersonal awareness: Empathy, ability to notice,

interpret, anticipate other's concerns, understands
strengths and weakness or others, making others feel
comfortable, influence others, gain others' support for
ideas, proposals, projects & solutions
12.2

Collaborative relationships: acknowledging others'

perspectives, showing interest in others, express gratitude
12.3
& appreciation for support, ability to develop, maintain &
strengthen relationships, providing assistance & support

Customer Orientation: Win the confidence of customers

(internal & external), demonstrates concern for satifying
their needs, finding a win-win situation, measure & track
customer satisfaction, presents cheeful, positive manners
to customers
12.4
13 Business Competentcies

Problem Solving: Diagnostic information gathering,

analytical thinking using logical, systematic, sequential
approach, identifying abnormalities, differential
diagnostics, technical expertise, forward thinking
13.1

Entrepreneurial orientation: Self-drive & intiative,

seizing opportunties, stays abreast of business, market
information, fostering innovation, promotes
entrepreneurial behavior in others, Decisiveness - Tough &
timely decisions
13.2
 Result Orientation: Stretch goals, develops clear goals for
projects, finds ways to measure goals, maintains
commitment to accomplish the goal, focus on processes to
achieve the goals
13.3
Thoroughness: Ensures correct & accurate information,
verifies data & information, sets procedures to ensure
highest quality of work, carefully prepares presentations,
Data accuracy
13.4
13.5 Decisiveness: Tough & timely decisions,
14 Self Management

Self- confidence: Conceptual & intellectual ability, ready

to change, Agile, can-do attitude, updating knowledge,
14.1

Stress Management: Self-control under pressure, keep

calm under stress, handling multiple tasks, maintains
sense of humor, manages own behavior under stress
14.2
Credibility: demonstrates as responsible, reliable &
trustworthy, does what is commited, respects
confidentiality, honest & forthright, owning responsibiilty,
no blaming
14.3
Leaders only

Value Stream Functional

Tool Setters Supervisors Team Leader
Leader Head

3 3 4 4 4

2 3 4 4 4

2 3 4 4 4
2 3 4 4 4
NA NA NA NA NA

3 4 4 4 4

3 4 4 2 2
3 4 4 2 2
3 4 4 2 2
3 4 4 2 2

3 4 4 4 4

3 4 4 2 2
4 4 4 2 2
4 4 4 4 4
2 3 4 4 4

4 4 4 2 2

4 4 4 2 2
3 4 4 4 4

4 4 4 3 3

2 3 4 4 4
2 3 4 4 4

2 3 4 4 4

2 3 4 4 4
4 4 4 2 2
4 4 4 4 4
4 4 4 4 4
4 4 4 2 2
4 4 4 2 2
4 4 4 2 2
2 2 2 2 2
3 4 4 3 3
2 2 2 3 3
2 2 2 2 2
2 2 2 2 2
2 2 2 2 2
3 4 4 3 3
3 4 4 2 2
3 4 4 4 4
1 2 2 4 4
1 2 2 4 4
2 3 4 4 4
NA NA NA 2 2
NA NA NA 2 2
2 3 4 4 4
2 4 4 4 4
2 4 4 4 4
2 4 4 4 4
3 4 4 4 4
3 4 4 4 4
1 2 3 4 4
ORGANISA
TIONAL
FUNCTIONAL /TECHNICAL

SOFT SKILL Behavioural

PERSONAL
 1131
Jibin Jose

Sr. No. Criteria Supervisors

1 Literacy
Can read & write English, Marathi, Hindi

Conversant with MS Office - Word, Excel, Powerpoint, Outlook

Conversant with SAP

Conversant with I-way; I-planet
Conversant with Raypro/ Proplast
AutoCAD
2 Discipline
Punctuality, Sincerity, speed in action,
3 Operation knowledge/ Proficiency - Industrialization
Can read technical drawing
Can visualize based on the technical drawing
General awareness on Basic Lean Concepts
Aware of Work Station Design based on Ergonomics
Can do Motion study & Work element study
Can do Load balancing on the line
Can do Supermarket calculations
Can work on Internal Logistics
Can do Value Stream Mapping
Can do Process Mapping
Can do PFMEA & DFMEA
Knowledge & Application in Mecha-tronics
Updated with the trends in market
Awareness in Industrialization 4.0
Knowledge on Application of the parts produced
Liaisoning with SPM manufacturers
Machine building knowledge
Can integrate Flow concepts with IT
Can trouble shoot problems in SPM
Exposure to 5 Core tools
Can develop Standards
Can create SoP, standard sequene & Future state map
Knowledge on Molding process
Knowledge on assembly process
Knowledge on Utility equipments

4 Operation knowledge/ Proficiency - Metal

 Can read technical drawing 3
Can operate bending & stamping machine 4
Can Operate Heat treatment plant 4
Is aware of principle of operation of machines 4
Can identify/ discriminate different raw materials 4
Can adjust process parameters based on materials 4
Can teach the bending machines 4
Can trouble shoot the bending machine 3
Can trouble shoot the heat treament plant 3
Knowledge on Utility equipments 4
Can operate the Slat spray test machine 4
Is exposed to tool manufacturing 3
Can trouble shoot problems pertained to tools 3
Can read tool drawing 3
Can read part drawing and work on tool design 3
Knowledge on Coating/ passivation procedures 3

5 ATOMS
Aware of 7 elements of ATOMS 3
Can practice 5S in his desk// workstation 3
Can teach others on 5S practices 3
Can adapt Flow concepts 3
Can teach others the flow concepts 3
Aware of QC tools & application 3
Aware of SPC calculations & its applications 3
Aware of Six Sigma/ DoE/ 3
Can do Motion study & Work element study 3
Can do Value Stream mapping 3
Can identify Wastes & the root cause for the same 3
Can minimize/ eliminate Wastes in the process 3
Can reduce throughput time 3
Can do calculations for Standard WIP/ Supermarket 3
Aware of Kanban & its calculations 3
Aware of Internal logistics/ container calculations 3
Can design workstation based on ergonomics 3
Can do process optimization 3
Aware of TPM - its main 5 pillars 3
Can motivate teams on Idea generation/ Kaizens 3

6 Dealing with people

 Establishing focus - Aligning the functional goal with strategy of
Behaviora
the organization, creating stretch, PMS, setting & sharing of
l
goals, feedback

Motivational support - People development (acknowledges,

recognizes, energizes, address morale issues, pep talks, provide
insights)

Fostering teamwork - lead by example, demonstrate, bringing

synergy, learn together, promoting cooperation, fair treatment

Empowering others - Effective delegatoin, convey confidence in

capabilities, allowing freedom to accomplish tasks, encouraging
team to resolve problems on their own

Managing Change - establish structures for orderly

implementation of change, ability to look ahead, taking lead in
setting new directions, look for innovative solutions, supports
various change management activities

12 Communication & Influencing

Communication - attention to communication, active listening,

sharing of information, expresses ideas concisely,
summarization, persuvasive communication, tailored
communication to reach audience effectively.

Interpersonal awareness: Empathy, ability to notice, interpret,

anticipate other's concerns, understands strengths and weakness
or others, making others feel comfortable, influence others,
gain others' support for ideas, proposals, projects & solutions

Collaborative relationships: acknowledging others'

perspectives, showing interest in others, express gratitude &
appreciation for support, ability to develop, maintain &
strengthen relationships, providing assistance & support

Customer Orientation: Win the confidence of customers

(internal & external), demonstrates concern for satifying their
needs, finding a win-win situation, measure & track customer
satisfaction, presents cheeful, positive manners to customers

7 Business Competentcies
Problem Solving: Diagnostic information gathering, analytical
thinking using logical, systematic, sequential approach,
identifying abnormalities, differential diagnostics, technical
expertise, forward thinking
 Entrepreneurial orientation: Self-drive & intiative, seizing
opportunties, stays abreast of business, market information,
fostering innovation, promotes entrepreneurial behavior in
others, Decisiveness - Tough & timely decisions

Result Orientation: Stretch goals, develops clear goals for

projects, finds ways to measure goals, maintains commitment to
accomplish the goal, focus on processes to achieve the goals

Thoroughness: Ensures correct & accurate information, verifies

data & information, sets procedures to ensure highest quality of
work, carefully prepares presentations, Data accuracy

Decisiveness: Tough & timely decisions,

8 Self Management

Self- confidence: Conceptual & intellectual ability, ready to

change, Agile, can-do attitude, updating knowledge,

Stress Management: Self-control under pressure, keep calm

under stress, handling multiple tasks, maintains sense of humor,
manages own behavior under stress

Credibility: demonstrates as responsible, reliable &

trustworthy, does what is commited, respects confidentiality,
honest & forthright, owning responsibiilty, no blaming
 1111
Detlef Boehler
Value Stream Functional
Team Leader
Leader Head

4 4

4 4

3 3
3 2
3 3
3 2

4 4

4 4
4 4
3 4
3 3
3 4
3 3
3 3
3 3
3 3
3 3
3 3
3 3
3 3
3 3
4 4
4 4
3 3
3 3
3 4
3 3
3 3
3 3
2 2
3 3
3 3
4
4
4
4
3
3
3
3
3
3
4
4
4
3
3
3
3
3
3
4
3 4

3 4

3 4

3 4

3 4

3 4

3 4

3 4

3 4

3 4
3 4

3 4

3 4

3 4

3 4

3 4

3 4
 1023 1192
Nagraj.A. Naik Ravindra Ghare
Functional Head Team Leader

Bending
Sr. No. Competancy Functional Head engineer
1 Bending Process
Can operate Bending machines NA 4
1.1
Can set the Process Paramators NA 4
1.2
Can operate & Set the straightner NA 4
1.3
Can operate & Set the Decoiler NA 4
1.4
Can load & Unload the Stamping tool on Bending Machine NA 4
1.5
Can load & Unload the Bending tool on Bending Machine NA 4
1.6
Can Mount & un Mount the Rear Cam NA 4
1.7
Can load the cams with respect to the Position NA 4
1.8
Can do the complet strip feeding & cycle Running NA 4
1.9
Can Fine Tune the setting of tool with respect to dimensional
NA 4
2 adjustment

Can do the self Inspection of Initial sample NA 4

2.1
Can use Gauges & fixtures 2 4
2.2
5s at work place 4 4
2.3
Trouble shooting of Machine 2 4
2.4
Trouble shooting of Tool 2 4
2.5
Can Handle Lubrication system of Machine & Tool 2 4
2.6
Can Handle Packging NA 4
2.7
Can generate PPM records NA 4
2.8
Can do Root cause analysis & rapid problem solving 4 4
2.9
Knows how to calculate & interpret OEE? 2 4
3
Knows the difference between T-OEE & OEE 2 4
3.1
Use of Hoist NA 4
3.2
Can discriminate/ identify raw materials 2 4
3.3
 Can Change the RM Coils NA 4
3.4
Can generate the MIS Reports NA 4
3.5
Can do Inprocess Inspection NA 4
3.6
Can do the Man power Planning based on production
4 4
3.7 requirment
Can Handle the Hand tools NA 4
3.8
Can do Inprocess Inspection NA 4
3.9
Creates and Implements Strategy 4 3
4

5 Heat Treatment Process

Can Operate the Heat Treatment Machine 2 NA
5.1
Can set the Process Paramators 2 NA
5.2
Can fine tune the process paramater s 2 NA
5.3
Can do the Belt Changing of main Convayer 2 NA
5.4
Can operate the Gas Bank & Acessories 2 NA
5.5
Can handle the Furnace cooling Management 2 NA
5.6
Can operate the spectro meter 2 NA
5.7
Can handle the part washing stations 2 NA
5.8
Can handle the RO station 2 NA
5.9
Can fine tune the paramaters based on Hardness required 2 NA
6
Can handle salt tank management 1 NA
6.1
Can do the salt transfer 1 NA
6.2
Can handle endo gas Management 1 NA
6.3
Can Handle the parts segrigation 1 NA
6.4
Can handle the Packging of parts for coating 1 NA
6.5
Can handle the final packging 1 NA
6.6
Can handle the Lable management 1 NA
6.7
Can handle Job card movements & Record 1 NA
6.8
Can handle the Internal material Movement 1 NA
6.9
 Can Handle the Hardness Tester ( HRC ) 1 NA
7
Can Trouble shoot the process 2 NA
7.1
Can trouble shoot the Machine 2 NA
7.2
Can do Basic Maintenance of Machine 2 NA
7.3
Can Handle LPG & N2 Gas management 1 NA
7.4
Can generate the MIS Reports 1 NA
7.5
Can do Inprocess Inspection 1 NA
7.6
Can do the Man power Planning based on production
4 NA
7.7 requirment
Can Handle the Hand tools NA NA
7.8
Can do Inprocess Inspection NA NA
7.9
Can discriminate/ identify raw materials 4 4
8
Can generate PPM records NA NA
8.1
Can do Root cause analysis & rapid problem solving 2 NA
8.2
Knows how to calculate & interpret OEE? 2 NA
8.3
Knows the difference between T-OEE & OEE 2 NA
8.4
Use of Hoist NA NA
8.5
5s at work place 4 NA
8.6

5 Literacy
5.1 Can read & write English, Marathi, Hindi 4 4
Conversant with MS Office - Word, Excel, Powerpoint,
Outlook
5.2 4 4
5.3 Conversant with Raypro/ Proplast 4 1
5.4 Can handle PDF & Auto Cad Drawings 4 2
5.5 Can Handle 3D Data 4 1
6 Discipline
6.1 Punctuality, Sincerity, speed in action, 4 4
7 Safety Awareness
7.1 Aware of PPE usage 2 4
7.2 Aware of Aspect-Impact procedures 2 4
7.3 Safe operation of machine/ peripherals 2 4
7.4 Aware of Near-miss reporting procedures 2 4
7.5 Trained in First Aid 2 4
7.6 Trained in fire fighting 2 4
7.7 Aware of color codes for trash bins 2 4
7.8 Aware of emergency evacuation plan/ procedures 4 4
7.9 Aware of importance of illumination 2 4
8 Aware of lubrication handling/ disposal procedures 2 4
8.1 Emergency situvation handling 4 4
9 Understanding of methods & standards
9.1 Can read & follow the SoP 2 4
9.2 Planning & delivery 2 4
9.3 Aware of machine start/stop procedure 2 4
9.4 Aware of Order closing procedure 2 4
9.5 Aware of MRN generating procedure 2 4
9.6 Can identify labels/ Carton specifications 2 4
9.7 Discriminate box & bag labels 2 4
9.8 Aware of packing methods 2 4
9.9 Aware of SMED/ Tool change procedure 2 4
10 Aware of QMS systems - General 4 4
10.1 Aware of QMS systems - Clausewise 4 4
Collaborate with PPC/ Maintenance team for maximized
10.2 utilization 2 4
10.3 Aware of lubrication handling/ disposal procedures 2 4
10.4 Aware of Set up Approval procedures 2 4
10.5 Aware of Process monitoring procedures 2 4
10.6 Can do PFMEA/ PPAP 2 4
10.7 Aware of 5 Core Tools 4 4
10.8 Follows set procedures 4 4
10.9 Gap analysis of established 4 4
11 Creates and implements strategy 4 4
12 ATOMS
12.1 Aware of 7 elements of ATOMS 4 4
12.2 Can practice 5S in his desk// workstation 4 4
12.3 Can teach other 5S practices 4 4
12.4 Can adapt Flow concepts 2 4
12.5 Can teach others the flow concepts 4 4
12.6 Aware of QC tools & application 2 4
12.7 Aware of SPC calculations & its applications 2 4
12.8 Aware of Six Sigma/ DoE/ 2 2
12.9 Can do Motion study & Work element study 4 4
13 Can do Value Stream mapping 4 2
13.1 Can identify Wastes & the root cause for the same 4 4
13.2 Can minimize/ eliminate Wastes in the process 2 4
13.3 Can reduce throughput time 2 4
13.4 Can do calculations for Standard WIP/ Supermarket 2 3
13.5 Aware of Kanban & its calculations 2 4
13.6 Aware of Internal logistics/ container calculations 2 4
13.7 Can design workstation based on ergonomics 4 4
13.8 Can do process optimization 2 4
13.9 Aware of TPM - its main 5 pillars 4 4
14 Can motivate teams on Idea generation/ Kaizens 4 4
 15 Communication Skills
8.1 Written 4 4
8.2 Verbal 4 4
8.3 Mail 4 4
16 EOHS
16.1 Aspect Impact Sheet 2 4
16.2 HIRA Sheet 2 4
16.3 Operational Control Procedure 2 4
17 Legal (Safety)
17.1 Emergency Response Plan 4 4
17.2 Fire Fighting 2 4
17.3 Waste Management 2 4
17.4 Work Permit System 4 2
17.5 Materail Safety data Sheet 4 4
 1275 1191 1277
Chetan Totad Sudhir Powar Shivaling Kamagouda
Team member Team Leader Team member

Tool
Maintenance Heat Treatment Heat Treatment
Engg. Engineer Engineer

4 1 1

3 1 1

3 1 1

3 1 1

3 1 1

3 1 1

3 1 1

3 1 1

3 1 1

4 1 1

4 1 1

4 1 1

4 1 1

2 NA NA

2 NA NA

2 NA NA

2 NA NA

2 NA NA

4 NA NA

2 NA NA

2 NA NA

4 NA NA

2 NA NA
2 NA NA

4 NA NA

2 NA NA

2 NA NA

4 NA NA

3 2 2

2 2 2

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4
NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

4 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

NA 4 4

4 4 4

3 4 4
1 1 1
2 1 1
1 NA NA

4 4 4

4 4 4
4 4 4
4 4 4
4 4 4
4 4 4
4 4
4 4 4
4 4 4
4 4 4
4 4 4
4 4 4

4 4 4
4 4 4
2 4 4
2 4 4
2 4 4
2 4 4
2 4 4
NA 4 4
4 4 4
4 4 4
4 4 4

4 4 4
4 4 4
4 4 4
2 4 4
2 4 4
4 4 4
4 4 4
2 2 2
2 2 2

4 4 4
4 4 4
4 4 4
4 4 4
2 4 4
2 4 4
2 4 4
2 2 2
2 4 4
2 2 2
4 4 4
4 4 4
1 4 4
1 3 3
NA 4 4
NA 4 4
NA 4 4
4 4 4
2 4 4
4 4 4
4 4 4
4 4 4
4 4 4

4 4 4
4 4 4
4 4 4

4 4 4
4 4 4
4 4 4
2 2 2
4 4 4
ORGANISATIONAL
FUNCTIONAL /TECHNICAL
Sr. No. Criteria Operators

1 Literacy
1.1 Can read & write English, Marathi, Hindi 2
Conversant with MS Office - Word, Excel, Powerpoint,
1.2
Outlook
1.3 Conversant with SAP
1.4 Conversant with Raypro/ Proplast
1.5 AutoCAD
2 Discipline
2.1 Punctuality, Sincerity, speed in action,
3 Operation knowledge/ Proficiency - Molding
3.1 Can operate Arburg machines
3.2 Can operatre Engel machines
3.3 Can discriminate/ identify raw materials
3.4 Can start/stop Hot runner system
Aware of temperature profile setting for different
3.5
materials
3.6 Counting & weighing of molded parts
3.7 Use of Hoist
3.8 Use of inspection gages
3.9 Use of Raypro/ Proplast
Operation of peripherals like robot, sprue-picker, MTC
3.10
etc.,
3.11 Can load & unload molds
3.12 Can set process parameters & Optimize
Aware of different temperature profiles for material
3.13
processing based on barrel capacity
3.14 Can calculate tonnage based on projected area
3.15 Can set hold-on period based on gate freeze time
Aware of relation between RPM/ cirumferencial speed/
3.16
surface speed
3.17 Apply & set fill phase & pressure phase judiciously
3.18 Can do Core setting considering safety
3.19 Apply cycle time saving techniques
3.20 Understand the PVT diagram
3.21 Can set Robot for new parts
3.22 Can make grippers for new parts
3.23 Can teach robot for new parts
 3.24 Can trouble shoot machine problems
3.25 Can trouble shoot process problems
3.26 Can trouble shoot Hot runner problems
3.27 Can trouble shoot chiller problems
3.28 Can trouble shoot MTC problems
3.29 Can trouble shoot Dryer/ loader problems
3.30 Can trouble shoot ejector/ core issues on mold
3.31 Can trouble shoot Robot problems
3.32 Can trouble shoot problems pertained to molds
3.33 Can read electrical schematic circuit diagram
3.34 Can read hydraulic circuit diagram & troubleshoot
3.35 Can read technical drawing
3.36 Can trouble shoot Compressors
3.37 Can trouble shoot DG Set problems
3.38 Can generate MIS reports from Raypro/Proplast
3.39 Knows how to calculate & interpret OEE?
3.40 Knows the difference between T-OEE & OEE
3.41 Can generate PPM records
3.42 Can do Root cause analysis & rapid problem solving
3.43 Aware of Quality tools
3.44 Can decide machine (buying) based on specifications
3.45
4 Operation knowledge/ Proficiency - QC Assembly
4.1 Knows to operate ATC machine
4.2 Knows to operate Pentagon manual machines
4.3 Knows to operate 657 Manual machine
4.4 Knows to operate Pentagon fully automatic machine
4.5 Knows to operate Hi-output ATC
4.6 Knows to opearte O ring insertion
4.7 Knows to operate Double lock toggle press
4.8 Knows to use gages for checking
4.9 Knows to do Push-in Pull-out test on QC
4.10 Knows to set Camera
4.11 Can teach Camera program
4.12 Can read leak test parameters in CTS
4.13 Can read leak test parameters in ATEQ
4.14 Can read ladder diagram in ATC
4.15 Can teach EPSON Robot in ATC
4.16 Aware of SMED procedures
4.17 Aware of lubricants to be used/ disposal procedures
Aware of difference between conductive & non-conductive
4.18
QC
4.19 Can trouble shoot problems pertained to assembly
4.20 Can trouble shoot camera problems
4.21 Can trouble shoot Robot problems
4.22 Can trouble shoot Leak tester problems
4.23 Can read schematic circuit diagrams

4.24 Can trouble shoot Pentagon made assembly machines

4.25 Can trouble shoot ATC

4.26 Can trouble shoot O Ring insertion machines
4.27 Aware of load balancing based on TAKT time
4.28 Can do Motion study & Work element study
4.29 Can do Root cause analysis & rapid problem solving
4.30 Aware of Quality tools
4.31 Aware of Flow/ Lean concepts

5 Operation knowledge/ Proficiency - Industrialization

5.1 Can read technical drawing

5.2 Can visualize based on the technical drawing
5.3 General awareness on Basic Lean Concepts
5.4 Aware of Work Station Design based on Ergonomics
5.5 Can do Motion study & Work element study
5.6 Can do Load balancing on the line
5.7 Can do Supermarket calculations
5.8 Can work on Internal Logistics
5.9 Can do Value Stream Mapping
5.10 Can do Process Mapping
5.11 Can do PFMEA & DFMEA
5.12 Knowledge & Application in Mecha-tronics
5.13 Updated with the trends in market
5.14 Awareness in Industrialization 4.0
5.15 Knowledge on Application of the parts produced
5.16 Liaisoning with SPM manufacturers
5.17 Machine building knowledge
5.18 Can integrate Flow concepts with IT
5.19 Can trouble shoot problems in SPM
5.20 Exposure to 5 Core tools
5.21 Aware of QMS/ TS/ ISO 14001 standards
5.22 Can develop Standards

5.23 Can create SoP, standard sequene & Future state map

5.24 Knowledge on Molding process

5.25 Knowledge on assembly process
5.26 Knowledge on Utility equipments
6 Operation knowledge/ Proficiency - Metal
6.1 Can read technical drawing
6.2 Can operate bending & stamping machine
 6.3 Can Operate Heat treatment plant
6.4 Is aware of principle of operation of machines
6.5 Can identify/ discriminate different raw materials
6.6 Can adjust process parameters based on materials
6.7 Can teach the bending machines
6.8 Can trouble shoot the bending machine
6.9 Can trouble shoot the heat treament plant
6.10 Knowledge on Utility equipments
6.11 Can operate the Slat spray test machine
6.12 Is exposed to tool manufacturing
6.13 Can trouble shoot problems pertained to tools
6.14 Can read tool drawing
6.15 Can read part drawing and work on tool design
6.16 Knowledge on Coating/ passivation procedures

Operation knowledge/ Proficiency - Fastener Assembly

7
7.1 Can read technical drawing
7.2 Can operate Ruhlamat river assembly machine
7.3 Can operate Collar punching machine
7.4 Can operate Glass fastener assembly machine
7.5 Can operate Hot melt machine
7.6 Can operate toggle press for collar punching
7.7 Can operate Swivel assembly machine
7.8 Can operate Edge Clip assembly machine
7.9 Can trouble shoot problems on assembly machines
7.10 Can do Motion study & Work element study
7.11 Can do Load balancing on the line
7.12 Can minimize cycle time and increase output
7.13 Aware of SMED procedures
7.14 Can do Root cause analysis & rapid problem solving
8 Understanding of methods & standards
8.1 Can read & follow the SoP
8.2 Planning & delivery
8.3 Aware of material pre-drying procedure
8.4 Aware of hot runner starting procedure
8.5 Aware of machine start/stop procedure
8.6 Aware of Order closing procedure
8.7 Aware of MRN generating procedure
8.8 Aware of material re-grinding procedure
8.9 Aware of hopper cleaning procedure
8.10 Aware of barrel purging procedure
8.11 Can identify labels/ Carton specifications
8.12 Discriminate box & bag labels
8.13 Aware of packing methods
8.14 Aware of SMED/ Mold change procedure
8.15 Aware of QMS systems - General
8.16 Aware of QMS systems - Clausewise
Collaborate with PPC/ Maintenance team for maximized
8.17
utilization
8.18 Aware of lubrication handling/ disposal procedures
8.19 Aware of Set up Approval procedures
8.20 Aware of Process monitoring procedures
8.21 Can do PFMEA/ PPAP
8.22 Aware of 5 Core Tools
9 Safety Awareness
9.1 Aware of PPE usage
9.2 Aware of Aspect-Impact procedures
9.3 Safe operation of machine/ peripherals
9.4 Aware of Near-miss reporting procedures
9.5 Trained in First Aid
9.6 Trained in fire fighting
9.7 Aware of color codes for trash bins
9.8 Aware of emergency evacuation plan/ procedures
9.9 Aware of importance of illumination
9.10 Aware of lubrication handling/ disposal procedures
10 ATOMS
10.1 Aware of 7 elements of ATOMS
10.2 Can practice 5S in his desk// workstation
10.3 Can teach other 5S practices
10.4 Can adapt Flow concepts
10.5 Can teach others the flow concepts
10.6 Aware of QC tools & application
10.7 Aware of SPC calculations & its applications
10.8 Aware of Six Sigma/ DoE/
10.9 Can do Motion study & Work element study
10.10 Can do Value Stream mapping
10.11 Can identify Wastes & the root cause for the same
10.12 Can minimize/ eliminate Wastes in the process
10.13 Can reduce throughput time
10.14 Can do calculations for Standard WIP/ Supermarket
10.15 Aware of Kanban & its calculations
10.16 Aware of Internal logistics/ container calculations
10.17 Can design workstation based on ergonomics
10.18 Can do process optimization
10.19 Aware of TPM - its main 5 pillars
10.20 Can motivate teams on Idea generation/ Kaizens
11 Dealing with people
 Establishing focus - Aligning the functional goal with
11.1 strategy of the organization, creating stretch, PMS, setting
& sharing of goals, feedback

Motivational support - People development

11.2 (acknowledges, recognizes, energizes, address morale
issues, pep talks, provide insights)

Fostering teamwork - lead by example, demonstrate,

11.3 bringing synergy, learn together, promoting cooperation,
fair treatment

Empowering others - Effective delegatoin, convey

11.4 confidence in capabilities, allowing freedom to accomplish
tasks, encouraging team to resolve problems on their own

Managing Change - establish structures for orderly

implementation of change, ability to look ahead, taking
11.5
lead in setting new directions, look for innovative
solutions, supports various change management activities

12 Communication & Influencing

Communication - attention to communication, active

listening, sharing of information, expresses ideas
12.1
concisely, summarization, persuvasive communication,
tailored communication to reach audience effectively.

Interpersonal awareness: Empathy, ability to notice,

interpret, anticipate other's concerns, understands
strengths and weakness or others, making others feel
comfortable, influence others, gain others' support for
ideas, proposals, projects & solutions
12.2

Collaborative relationships: acknowledging others'

perspectives, showing interest in others, express gratitude
12.3
& appreciation for support, ability to develop, maintain &
strengthen relationships, providing assistance & support

Customer Orientation: Win the confidence of customers

(internal & external), demonstrates concern for satifying
their needs, finding a win-win situation, measure & track
customer satisfaction, presents cheeful, positive manners
to customers
12.4
13 Business Competentcies
 Problem Solving: Diagnostic information gathering,
analytical thinking using logical, systematic, sequential
approach, identifying abnormalities, differential
diagnostics, technical expertise, forward thinking
13.1

Entrepreneurial orientation: Self-drive & intiative,

seizing opportunties, stays abreast of business, market
information, fostering innovation, promotes
entrepreneurial behavior in others, Decisiveness - Tough &
timely decisions
13.2
Result Orientation: Stretch goals, develops clear goals for
projects, finds ways to measure goals, maintains
commitment to accomplish the goal, focus on processes to
achieve the goals
13.3
Thoroughness: Ensures correct & accurate information,
verifies data & information, sets procedures to ensure
highest quality of work, carefully prepares presentations,
Data accuracy
13.4
13.5 Decisiveness: Tough & timely decisions,
14 Self Management

Self- confidence: Conceptual & intellectual ability, ready

to change, Agile, can-do attitude, updating knowledge,
14.1

Stress Management: Self-control under pressure, keep

calm under stress, handling multiple tasks, maintains
sense of humor, manages own behavior under stress
14.2
Credibility: demonstrates as responsible, reliable &
trustworthy, does what is commited, respects
confidentiality, honest & forthright, owning responsibiilty,
no blaming
14.3
Leaders only

Value Stream Functional

Tool Setters Supervisors Team Leader
Leader Head

3 3 3 4
ORGANISA
TIONAL
FUNCTIONAL /TECHNICAL

SOFT SKILL Behavioural

PERSONAL
Sr. No. Competancy Criteria

Can read & write English, Marathi, Hindi

Conversant with MS Office - Word, Excel, Powerpoint, Outlook

Literacy Conversant with SAP

Conversant with I-way; I-planet
Conversant with Raypro/ Proplast
AutoCAD
Discipline Punctuality, Sincerity, speed in action,
Can operate Arburg machines
Can operatre Engel machines
Can discriminate/ identify raw materials
Can start/stop Hot runner system
Aware of temperature profile setting for different material
Can operate annealing machine
Aware of GP 12 processes
Aware of different types of molding process (2K; insert)
Counting & weighing of molded parts
Use of Hoist
Use of inspection gages
Use of Raypro/ Proplast

Operation of peripherals like robot, sprue-picker, MTC etc.,

Can load & unload molds

Can set process parameters & Optimize
Aware of different temperature profiles for material processing
based on barrel capacity
Can calculate tonnage based on projected area
Can set hold-on period based on gate freeze time
Aware of relation between RPM/ cirumferencial speed/ surface
speed
Apply & set fill phase & pressure phase judiciously
Can do Core setting considering safety
Apply cycle time saving techniques
Understand the PVT diagram
 Can set Robot for new parts
Can make grippers for new parts
Can teach robot for new parts
Can trouble shoot machine problems
Can trouble shoot process problems
Operation knowledge/
Can trouble shoot Hot runner problems
Proficiency - Molding
Can trouble shoot chiller problems
Can trouble shoot MTC problems
Can trouble shoot Dryer/ loader problems
Can trouble shoot ejector/ core issues on mold
Can trouble shoot Robot problems
Can trouble shoot problems pertained to molds
Can read electrical schematic circuit diagram
Can read hydraulic circuit diagram & troubleshoot
Can read technical drawing
Can trouble shoot Compressors
Can trouble shoot DG Set problems
Can generate MIS reports from Raypro/Proplast
Knows how to calculate & interpret OEE?
Knows the difference between T-OEE & OEE
Can generate PPM records
Can do Root cause analysis & rapid problem solving
Aware of Quality tools
Can decide machine (buying) based on specifications
Is aware of SMED principles
Can discriminate internal & external activities
Ability to convert internal activities to external
Aware of die height adjustment/ shut height & daylight
Aware of using the right tool, giving the right torque
Can teach others on process adjustments
Can teach others on SMED
Can teach others on shift handling/ tier meeting
Can do PPAP exercise
Can support creating APQP
Can support PFMEA

Knows to operate ATC machine

Knows to operate Pentagon manual machines
Knows to operate 657 Manual machine
Knows to operate Pentagon fully automatic machine
 Knows to operate Hi-output ATC
Knows to opearte O ring insertion
Knows to operate Double lock toggle press
Knows to use gages for checking
Knows to do Push-in Pull-out test on QC
Knows to set Camera
Can teach Camera program
Can read leak test parameters in CTS
Can read leak test parameters in ATEQ
Can read ladder diagram in ATC
Can teach EPSON Robot in ATC
Aware of SMED procedures
Aware of lubricants to be used/ disposal procedures

Aware of difference between conductive & non-conductive QC

Operation knowledge/
Can trouble shoot problems pertained to assembly
Proficiency - QC Assembly
Can trouble shoot camera problems
Can trouble shoot Robot problems
Can trouble shoot Leak tester problems
Can read schematic circuit diagrams
Can trouble shoot Pentagon made assembly machines
Can trouble shoot ATC
Can trouble shoot O Ring insertion machines
Aware of load balancing based on TAKT time
Can do Motion study & Work element study
Can do Root cause analysis & rapid problem solving
Aware of Quality tools
Aware of Flow/ Lean concepts
Can able to conduct time and motion study
Can plan material feeding time & lot size
Aware of using the right tool, giving the right torque
Can do PPAP exercise
Can support creating APQP
Can support PFMEA

Can read technical drawing

Can visualize based on the technical drawing
General awareness on Basic Lean Concepts
Aware of Work Station Design based on Ergonomics
Can do Motion study & Work element study
Can do Load balancing on the line
 Can do Supermarket calculations
Can work on Internal Logistics
Can do Value Stream Mapping
Can do Process Mapping
Can do PFMEA & DFMEA
Knowledge & Application in Mecha-tronics
Operation knowledge/ Updated with the trends in market
Proficiency -
Industrialization Awareness in Industrialization 4.0
Knowledge on Application of the parts produced
Liaisoning with SPM manufacturers
Machine building knowledge
Can integrate Flow concepts with IT
Can trouble shoot problems in SPM
Exposure to 5 Core tools
Can develop Standards
Can create SoP, standard sequene & Future state map
Knowledge on Molding process
Knowledge on assembly process
Knowledge on Utility equipments

Can read technical drawing

Can operate bending & stamping machine
Can Operate Heat treatment plant
Is aware of principle of operation of machines
Can identify/ discriminate different raw materials
Can adjust process parameters based on materials
Can teach the bending machines
Can trouble shoot the bending machine
Operation knowledge/
Can trouble shoot the heat treament plant
Proficiency - Metal
Knowledge on Utility equipments
Can operate the Slat spray test machine
Is exposed to tool manufacturing
Can trouble shoot problems pertained to tools
Can read tool drawing
Can read part drawing and work on tool design
Knowledge on Coating/ passivation procedures

Can read technical drawing

Can operate Ruhlamat river assembly machine
Can operate Collar punching machine
Can operate Glass fastener assembly machine
 Can operate Hot melt machine
Can operate toggle press for collar punching
Can operate Swivel assembly machine
Operation knowledge/ Can operate Edge Clip assembly machine
Proficiency - Fastener Can trouble shoot problems on assembly machines
Assembly Can do Motion study & Work element study
Can do Load balancing on the line
Can minimize cycle time and increase output
Aware of SMED procedures
Can do Root cause analysis & rapid problem solving

Can read & follow the SoP

Planning & delivery
Aware of material pre-drying procedure
Aware of hot runner starting procedure
Aware of machine start/stop procedure
Aware of Order closing procedure
Aware of MRN generating procedure
Aware of material re-grinding procedure
Aware of hopper cleaning procedure
Aware of barrel purging procedure
Can identify labels/ Carton specifications
Discriminate box & bag labels
Aware of packing methods
Aware of SMED/ Mold change procedure
Aware of QMS systems - General
Aware of QMS systems - Clausewise
Collaborate with PPC/ Maintenance team for maximized
Understanding of utilization
methods & standards Aware of lubrication handling/ disposal procedures
Aware of Set up Approval procedures
Aware of Process monitoring procedures
Can do PFMEA/ PPAP
Aware of 5 Core Tools
Aware of ATOMS
Aware of closing an order in Raypro/ SAP
Aware of declaring rejection in SAP
Aware of Poke-yoke checking procedure
Aware of ECN and its implementation procedures
 Aware of NC procedures
Aware of reconciling Estimate/ Raypro/ SAP parameters with
respect to production - time; resources etc
Aware of entering Calendar in Raypro/ Proplast

Aware of PPE usage

Aware of Aspect-Impact procedures
Safe operation of machine/ peripherals
Aware of Near-miss reporting procedures
Trained in First Aid
Safety Awareness Trained in fire fighting
Aware of color codes for trash bins
Aware of emergency evacuation plan/ procedures
Aware of importance of illumination
Aware of lubrication handling/ disposal procedures

Aware of 7 elements of ATOMS

Can practice 5S in his desk// workstation
Can teach others on 5S practices
Can adapt Flow concepts
Can teach others the flow concepts
Aware of QC tools & application
Aware of SPC calculations & its applications
Aware of Six Sigma/ DoE/
Can do Motion study & Work element study
Can do Value Stream mapping
Can identify Wastes & the root cause for the same
ATOMS Can minimize/ eliminate Wastes in the process
Can reduce throughput time
Can do calculations for Standard WIP/ Supermarket
Aware of Kanban & its calculations
Aware of Internal logistics/ container calculations
Can design workstation based on ergonomics
Can do process optimization
Aware of TPM - its main 5 pillars
Can motivate teams on Idea generation/ Kaizens
 Establishing focus - Aligning the functional goal with strategy of
Behaviora
the organization, creating stretch, PMS, setting & sharing of
l
goals, feedback

Motivational support - People development (acknowledges,

recognizes, energizes, address morale issues, pep talks, provide
insights)

Fostering teamwork - lead by example, demonstrate, bringing

synergy, learn together, promoting cooperation, fair treatment
Dealing with people

Empowering others - Effective delegatoin, convey confidence in

capabilities, allowing freedom to accomplish tasks, encouraging
team to resolve problems on their own

Managing Change - establish structures for orderly

implementation of change, ability to look ahead, taking lead in
setting new directions, look for innovative solutions, supports
various change management activities

Communication - attention to communication, active listening,

sharing of information, expresses ideas concisely,
summarization, persuvasive communication, tailored
communication to reach audience effectively.

Interpersonal awareness: Empathy, ability to notice, interpret,

anticipate other's concerns, understands strengths and weakness
or others, making others feel comfortable, influence others,
gain others' support for ideas, proposals, projects & solutions

Communication &
Influencing
Collaborative relationships: acknowledging others'
perspectives, showing interest in others, express gratitude &
appreciation for support, ability to develop, maintain &
strengthen relationships, providing assistance & support

Customer Orientation: Win the confidence of customers

(internal & external), demonstrates concern for satifying their
needs, finding a win-win situation, measure & track customer
satisfaction, presents cheeful, positive manners to customers

Problem Solving: Diagnostic information gathering, analytical

thinking using logical, systematic, sequential approach,
identifying abnormalities, differential diagnostics, technical
expertise, forward thinking
 Entrepreneurial orientation: Self-drive & intiative, seizing
opportunties, stays abreast of business, market information,
fostering innovation, promotes entrepreneurial behavior in
others, Decisiveness - Tough & timely decisions

Business Competentcies
Result Orientation: Stretch goals, develops clear goals for
projects, finds ways to measure goals, maintains commitment to
accomplish the goal, focus on processes to achieve the goals

Thoroughness: Ensures correct & accurate information, verifies

data & information, sets procedures to ensure highest quality of
work, carefully prepares presentations, Data accuracy

Decisiveness: Tough & timely decisions,

Self- confidence: Conceptual & intellectual ability, ready to
change, Agile, can-do attitude, updating knowledge,

Stress Management: Self-control under pressure, keep calm

under stress, handling multiple tasks, maintains sense of humor,
Self Management manages own behavior under stress

Credibility: demonstrates as responsible, reliable &

trustworthy, does what is commited, respects confidentiality,
honest & forthright, owning responsibiilty, no blaming
 Quality
Operators Supervisors Team Leader
Inspectors

2 2 4 4

N N 3 4

N 1 2 3
N N N N
N 2 3 3
N N N N
4 4 4 4
4
4
4
4
4

4
4
4
3

4
3

2
3

3
4
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